Grid structures

ABSTRACT

Integrally formed grid structures made of composite graphite-epoxy material are disclosed in which graphite fibers extend three-dimensionally in at least three different directions.

This application is a division of Ser. No. 286,120, filed on Dec. 19,1988.

TECHNICAL FIELD

This invention relates generally to the fabrication of grid structures,and more particularly to the fabrication of grid structures made from acomposite material consisting of fibers embedded in a matrix in whichthe fibers extend in three different directions.

BACKGROUND ART

Grid structures have been proposed for applications requiringexceptionally light weight and high strength, e.g., for supportingantennas and reflective surfaces in extraterrestrial space. It hasfurther been proposed to fabricate such grid structures fromfiber-reinforced matrix materials. In general, a fiber-reinforced matrixmaterial could be formulated using fibers made of graphite, aramide,fiberglass, ceramic material, metallic material or thermoplasticmaterial, and using a matrix made of a thermosetting resin (e.g., epoxy,polyester, phenolic, polymide) or a thermoplastic material.Graphite-epoxy composites are well-known fiber-reinforced matrixmaterials.

In the prior art, grid structures were typically fabricated by bondingtogether separate panels (called "grid sections"), which could be eitherplanar or curved, to form structures of "eggcrate" or "honeycomb"configuration.

In a typical grid structure of eggcrate configuration in the prior art,separate grid sections appear to intersect each other so as to defineinterstices that are arrayed in a geometrically regular patternresembling an eggcrate. However, the intersecting grid sections of atypical eggcrate-type grid structure of the prior art do not actuallyintersect each other in the sense that two abstract mathematicalsurfaces (planar or curved) can penetrate each other without breachingthe integrity of either surface. When two grid sections of a typicaleggcrate-type grid structure of the prior art "intersect" each other, itis generally necessary that at least one grid section (or a portionthereof) be cut so that the other grid section (or a portion thereof)can be positioned in the cut. The two "intersecting" grid sections arethen bonded to each other by an adhesive bonding material, which isordinarily spread along edges of the cut.

In a typical grid structure of honeycomb configuration in the prior art,separate grid sections are corrugated so as to have flat surfaceportions that are usually equally spaced with respect to each other. Theflat surface portions of each grid section are positioned in contactwith corresponding flat surface portions of adjacent grid sections, andthe contacting surface portions of the adjacent grid sections areadhesively bonded together to define interstices between the adjacentgrid sections. The resulting interstices are arrayed in a geometricallyregular pattern resembling a honeycomb.

In a conventional eggcrate-type or honeycomb-type of grid structure, thestrength of the grid structure necessarily depends upon the strength ofthe adhesive bonds by which the intersecting or contacting grid sectionsare secured to each other. In general, a grid structure of the eggcratetype is most prone to failure at the places where cuts have been made inintersecting grid sections, and a grid structure of the honeycomb typeis most prone to failure at the places where contacting surface portionsof adjacent grid sections are bonded together.

In a conventional eggcrate-type or honeycomb-type of grid structure, theweight of the adhesive bonding material that is applied where separategrid sections intersect or make contact with each other generallyintroduces a nonuniformity in weight distribution throughout the gridstructure. Furthermore, inhomogeneities occurring in the adhesivebonding material can cause structural weaknesses in the grid structure.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a technique forfabricating a grid structure from a composite material consisting offibers embedded in a matrix in which the fibers extend in at least threedifferent directions.

It is a feature of a grid structure according to the present inventionthat substantial uniformity in strength is obtained throughout the gridstructure, and that variations in weight distribution throughout thegrid structure are practically insignificant.

In accordance with a preferred embodiment of the present invention, agrid structure made from a composite material consisting of fibersembedded in a matrix (e.g., a graphite-epoxy composite material) isfabricated by a process that includes the following steps: (a) weaving afilament made of fibrous material into a pattern defining interstices ofthe grid structure, (b) winding filaments made of fibrous material ontomandrels that conform in cross-sectional configuration to theinterstices of the grid structure as defined by the woven filament, (c)inserting the mandrels with the filaments wound thereon intocorresponding interstices of the grid structure, (d) impregnating thefibrous material with a liquid matrix material, (e) compressing thefibrous material impregnated with liquid matrix material between themandrels in adjacent interstices, (f) curing the matrix material to formthe grid structure, and (g) removing the mandrels from the intersticesafter the matrix material has cured.

DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of a three-dimensional grid structure ofeggcrate configuration made from a graphite-epoxy composite material inaccordance with the present invention.

FIG. 2 is a perspective view of a loom for use in weaving a graphitefilament into a grid structure having the configuration shown in FIG. 1.

FIG. 3 is a representation in perspective view of three successive pathsover the loom shown in FIG. 2 by a graphite filament being woven into agrid structure having the configuration shown in FIG. 1.

FIG. 4 is a perspective view of a mandrel being wound with a graphitefilament for insertion into an interstice defined by intersecting planesformed by weaving a graphite filament on the loom shown in FIG. 2.

FIG. 5 is a perspective view of a mandrel being wrapped with a tapecomprising resin-impregnated graphite fibers for insertion into aninterstice defined by intersecting planes formed by weaving a graphitefilament on the loom .shown in FIG. 2.

FIG. 6 is a perspective view illustrating mandrels (which may befilament-wound or tape-wrapped, as shown in FIGS. 4 and 5, respectively)being inserted into corresponding interstices defined by intersectingplanes formed by weaving a graphite filament on the loom shown in FIG.2.

FIG. 7 is a representation in perspective view of a technique wherebythe graphite filaments on the loom and on the mandrels shown in FIG. 6are impregnated with epoxy resin.

FIG. 8 is a perspective view illustrating resin-impregnated graphitefilaments compressed together on the loom and mandrels shown in FIG. 6,and illustrating the loom and mandrels with the compressed graphitefilaments thereon being inserted into an oven for curing of the resin.

FIG. 9 is a cross-sectional view along line 9--9 of FIG. 8.

FIG. 10 is a fragmentary cross-sectional view schematically illustratingfilament-wound mandrels in a row of interstices defined by intersectingplanes formed by the graphite filament woven on the loom shown in FIG.6.

FIG. 11 is a fragmentary cross-sectional view as in FIG. 10 illustratinga technique for removing the mandrels from the interstices after theresin has been cured.

FIG. 12 is a perspective view illustrating a technique using a diamondwire saw for trimming end portions from a three-dimensional gridstructure made according to the present invention.

FIG. 13 is a perspective view showing two grid structures as illustratedin FIG. 1 being joined together to form a larger grid structure.

FIG. 14 illustrates three successive steps in a technique for joiningtwo grid structures together to form the larger grid structure shown inFIG. 13.

FIG. 15 is a perspective view schematically illustrating an alternativetechnique according to the present invention, whereby the intersectingplanes defining the interstices of a three-dimensional grid structure ofeggcrate configuration are formed by stacking tapes of resin-impregnatedgraphite fibers rather than by weaving a graphite filament as in FIG. 6.

FIG. 16 is a sketch in perspective view of the grid structure of FIG. 1wherein the interstices of the grid structure are of square cylindricalconfiguration.

FIG. 17 is a sketch in perspective view of an alternative configurationfor a grid structure according to the present invention wherein theinterstices of the grid structure are of rhomboidally cylindricalconfiguration.

FIG. 18 is a sketch in perspective view of another alternativeconfiguration for a grid structure according to the present inventionwherein the interstices of the grid structure are of triangularlycylindrical configuration.

FIG. 19 is a sketch in perspective view of a grid structure of arcuateconfiguration according to the present invention.

FIG. 20 is a sketch in perspective view of an alternative configurationfor a grid structure according to the present invention, wherein each ofthe interstices of the grid structure is defined by two concentricallycylindrical surfaces having different radii with respect to acylindrical axis and by two planar surfaces extending radially from thecylindrical axis.

FIG. 21 is a plan view of a loom for use in fabricating a rhomboidalgrid structure as sketched in FIG. 17.

FIG. 22 is a perspective view of a loom for use in fabricating atriangular grid structure as sketched in FIG. 18.

FIG. 23 is a representation in perspective view of the path of agraphite filament being woven on the loom shown in FIG. 22.

FIG. 24 is a perspective view of a loom for use in fabricating anarcuate grid structure as sketched in FIG. 19.

FIG. 25 is a perspective view of a mandrel for use on the loom shown inFIG. 24.

FIG. 26 is a representation in perspective view of the path of agraphite filament being woven on the loom shown in FIG. 24.

FIG. 27 is a perspective view illustrating a technique using a diamondwire saw for trimming end portions from an arcuate grid structure assketched in FIG. 19.

FIG. 28 is a perspective view of the completed arcuate grid structureafter having been trimmed as shown in FIG. 19.

FIG. 29 is a perspective view of a loom for use in fabricating a gridstructure having coaxial arcuate rows of different radii as sketched inFIG. 20.

FIG. 30 is a cross-sectional view along line 30--30 of FIG. 29.

FIGS. 31A, 31B and 31C schematically illustrate three successive stepsin using the loom of FIG. 29 to fabricate a grid structure as sketchedin FIG. 20.

FIG. 32 is a perspective view of an alternative embodiment of a gridstructure according to the present invention, wherein the graphitefilament woven to form the intersecting planes of the grid structureextends in two different directions on each plane, and wherein these twodifferent directions are each oblique with respect to the cylindricalaxes of the interstices defined by the intersecting planes.

FIG. 33 is a perspective view of another alternative embodiment of agrid structure according to the present invention, wherein the graphitefilament woven to form the intersecting planes of the grid structurecrisscrosses itself to form two plies for each intersecting plane.

FIG. 34 is a perspective view of a loom for weaving a graphite filamentinto a configuration as shown in FIG. 33.

FIG. 35 is a perspective view of a stack of looms of the type shown inFIG. 34 mounted on a base loom for fabricating an elongate gridstructure according to the present invention.

FIG. 36 is a perspective view in exploded detail of clamping devices forapplying compressional forces to mandrels in the interstices of the gridstructure formed on the stack of looms shown in FIG. 35.

FIG. 37 is a broken-away perspective view of an oven for curing epoxyresin saturating the graphite filaments of the grid structure formed onthe stack of looms shown in FIG. 35.

FIG. 38 is a cross-sectional view along line 38--38 of FIG. 37.

FIG. 39 is a cross-sectional view along line 39--39 of FIG. 37.

FIG. 40 is a simplified perspective view of a continuous-processapparatus for fabricating grid structures according to the presentinvention.

FIG. 41 is a perspective view of the continuous-process apparatus ofFIG. 40 showing additional features of the apparatus, wherebycompressional forces are applied against mandrels in the intersticesdefined by intersecting planes formed by stacked tapes of epoxyresin-impregnated graphite fibers.

FIG. 42 is a simplified elevation view of the continuous-processapparatus of FIG. 40.

FIG. 43 is a diagrammatic summarization of the steps in the process ofmanufacturing a grid structure according to the present invention usingthe continuous-process apparatus of FIG. 40.

FIG. 44 is a perspective view, partially in phantom outline, of aproposed spacecraft on which grid structures according to the presentinvention would be utilized as illustrated.

BEST MODE OF CARRYING OUT THE INVENTION

A three-dimensional grid structure of eggcrate configuration made from agraphite-epoxy composite material in accordance with the presentinvention is illustrated in FIG. 1. The grid structure of FIG. 1 isfabricated by weaving a filament made of graphite fibers on a loom 10according to a predetermined pattern as shown in FIG. 2. The loom 10comprises a planar frame 11 upon which a plurality of verticallyextending posts 12 are mounted to enclose a generally rectangularcylindrical volume. In the particular embodiment shown in FIG. 2, theframe 11 is of generally square configuration, and the volume enclosedby the posts 12 is a square cylindrical volume.

In FIG. 3, three successive iterations of a pattern in which thefilament is woven around the posts 12 of the loom 10 are shown. The gridstructure thereby formed on the loom 10 has a so-called "eggcrate"configuration in which mutually orthogonal planar grid sectionsintersect each other to define square cylindrical interstices. Themutually orthogonal planar grid sections of the grid structure formed onthe loom 10 "intersect" each other in the sense that portions of thegraphite filament forming any one planar grid section pass through theplanar grid sections that are orthogonal thereto. It is a feature of thepresent invention that the "intersecting" grid sections forming the gridstructure are constructed from a single graphite filament. In contrastwith typical eggcrate-type grid structures of the prior art, gridsections of a grid structure according to the present invention are notcut to receive "intersecting" grid sections.

The pattern as indicated in FIG. 3 in which the graphite filament iswoven around the posts 12 of the loom 10 results in a relatively simpleweave in which those portions of the graphite filament extending in onedirection form a first set of mutually parallel grid sections, and thoseportions of the graphite filament extending in a direction orthogonal tothe first set of grid sections form a second set of mutually parallelgrid sections. The weaving pattern results in square cylindricalinterstices bounded by the intersecting first and second sets of gridsections.

In order to form a three-dimensional woven grid structure, a pluralityof mandrels 13 are individually wound with graphite filaments as shownin FIG. 4. Each of the mandrels 13 is elongate about a longitudinalaxis, and has a transverse cross section that is configured anddimensioned so as to enable the mandrel 13 with a graphite filamentwinding thereon to fit tightly into a corresponding one of theinterstices formed by the intersecting grid sections. As an alternativeto the procedure of winding a graphite filament around each mandrel 13,a tape comprising graphite fibers impregnated with epoxy resin (i.e.,so-called "prepreg" tape) could be wrapped around each mandrel 13 asshown in FIG. 5. The mandrels 13 (whether filament-wound ortape-wrapped) are then inserted into the corresponding intersticesformed by the intersecting grid sections.

As seen in FIG. 6, the mandrels 13 are inserted into the correspondinginterstices of the grid structure formed on the loom 10 so that any twoadjacent mandrels 13 on opposite sides of any particular planar gridsection are oriented with 90-degree rotations relative to each otherabout their longitudinal axes. In this way, vertically extendinggraphite filaments (or "prepreg" graphite fibers) on the mandrels 13 arebrought into contact with horizontally extending portions of thegraphite filament wound around the posts 12 on the loom 10 to form theintersecting grid sections. After the mandrels 13 have been insertedinto the interstices, the graphite filaments (and the "prepreg" graphitefibers, if tape-wrapped mandrels 13 are used) are then impregnated witha liquid epoxy resin.

For the grid structure formed on the loom 10 shown in FIG. 6, all theinterstices are of square cylindrical configuration with substantiallyidentical dimensions. Therefore, all the mandrels 13 are identicallyconfigured and dimensioned so as to be interchangeable with each other.The mandrels 13 (whether filament-wound or tape-wrapped) are insertedinto the interstices so that longitudinally extending portions of thegraphite filaments on filament-wound mandrels 13, or longitudinallyextending graphite fibers on "prepreg" tape-wrapped mandrels 13, areoriented generally orthogonally with respect to the portions of thegraphite filament comprising the grid sections formed on the loom 10.

A technique is schematically illustrated in FIG. 7 for applying liquidepoxy resin to the portions of the graphite filament comprising the gridsections formed on the loom 10, and to the graphite filaments (or"prepreg" graphite fibers) on the mandrels 13. Thus, liquid epoxy resinis shown being poured from a can 14 to saturate the graphite filaments.Clamping devices mounted on the frame 11 of the loom 10 are then used tocompress the epoxy-saturated graphite filaments on the mandrels 13 andon the contacting portions of the graphite filament woven around theposts 12 on the loom 10 together.

Referring again to FIG. 2, two clamping devices are mounted on the frame11 in order to apply compressional forces in two mutually orthogonaldirections against the mandrels 13 in the interstices defined by thegrid sections formed on the loom 10. Each clamping device comprises afixed abutment member 15, a movable abutment member 16, and an anchoringmember 17. The fixed abutment member 15 of each clamping device issecured (as by screws) to the frame 11 inside the cylindrical volumeenclosed by the vertical posts 12, and extends horizontally parallel toa row of the posts 12 defining one side of the cylindrical volume. Themovable abutment member 16 of the same clamping device is positionedinside the cylindrical volume adjacent a row of the posts 12 defining anopposite side of the same volume, so that the fixed abutment member 15and the movable abutment member 16 face each other. The anchoring member17 is secured (as by screws) to the frame 11 outside the cylindricalvolume enclosed by the posts 12. Adjustment screws 18, which extendthrough the anchoring member 17 and between adjacent posts 12 into themovable abutment member 16, enable the movable abutment member 16 to betranslated laterally over the surface of the frame 11 toward or awayfrom the fixed abutment member 15. Two such clamping devices are mountedon the frame 11 at right angles to each other.

As shown in FIG. 6, the mandrels 13 (whether filament-wound ortape-wrapped), when inserted into the interstices defined by the gridsections formed on the loom 10, assume a checkerboard-like arrangement,which ensures that the vertically extending graphite filaments on themandrels 13 come into contact with corresponding portions of thehorizontally extending graphite filament woven around the posts 12.After the graphite filaments have been saturated with liquid epoxy resinas indicated in FIG. 7, a cover frame 19 is fitted over the posts 12 asshown in FIG. 8.

The cover frame 19 is configured like the frame 11 upon which the posts12 are mounted, except that the cover frame 19 has recesses positionedand dimensioned to receive top ends of the posts 12 when the cover frame19 is fitted over the posts 12. Two clamping devices are mounted on thecover frame 19 in substantially the same manner as the two previouslymentioned clamping devices are mounted on the frame 11. Each clampingdevice on the cover frame 19 comprises a fixed abutment member 15', amovable abutment member 16' and an anchoring member 17', which areindicated in phantom view in FIG. 8. Adjustment screws 18', which extendthrough the anchoring member 17' and between adjacent posts 12 into themovable abutment member 16', so as to enable the movable abutment member16' to be translated laterally over the surface (i.e., the undersurfacein the perspective of FIG. 8) of the cover frame 19 toward or away fromthe fixed abutment member 15'. The cover frame 19 is fitted over theposts 12 so that the fixed abutment members 15' and the movable abutmentmembers 16' of the two clamping devices mounted on the cover frame 19are located inside the cylindrical volume enclosed by the posts 12, andso that the anchoring members 17' of the same two clamping devices arelocated outside the cylindrical volume adjacent corresponding edges ofthe cover frame 19.

When the cover frame 19 is in place over the posts 12, the adjustmentscrews 18 and 18' are tightened so as to apply compressional forces nearthe top and bottom ends, respectively, of the outermost mandrels 13around the periphery of the checkerboard-like arrangement of themandrels 13. A cross-sectional view of the loom 10 with the cover frame19 in place, and with the clamping devices in operation, is shown inFIG. 9. After the adjustment screws 18 and 18' have been tightened toapply the compressional forces to the mandrels 13, the entire loom 10with the cover frame 19 in place thereon is then inserted into an oven20 in which the epoxy resin that has impregnated the graphite fibers iscured. Typically, the curing of a graphite-epoxy material requires thatthe oven 20 be maintained at a temperature of approximately 120° C. to180° C. for one to two hours.

After the epoxy resin has been cured, the loom 10 is taken from the oven20, and the cover frame 19 is removed. Then, the graphite fibers in thevicinity of the posts 12 are cut by a conventional cutting technique toenable the grid structure to be lifted away from the frame 11. The gridstructure now comprises a plurality of intersecting planar grid sectionsmade of a composite graphite-epoxy material, where each grid sectionconsists of two plys (i.e., a first ply and a second ply) that areinextricably fused together. The first ply consists of the verticallyextending graphite filaments received from the mandrels 13, and thesecond ply consists of portions of the graphite filament that were wovenhorizontally around the posts 12 on the loom 10. Although the two pliesare inextricably fused together as a result of the curing of the epoxyresin, it is instructive to illustrate the two plies as visuallydistinguishable from the each other in FIG. 10.

A technique is illustrated in FIG. 11 for removing the mandrels 13 fromthe interstices of the grid structure. As shown in FIG. 11, a cut ismade in the first ply at the top end of each mandrel 13 by aconventional cutting tool 21, so that the mandrel 13 can be lifted outof the interstice. It is convenient to provide holes 22 adjacent theends of the mandrels 13 to facilitate lifting of the mandrels 13 out ofthe interstices by using an appropriate tool 23, as indicated in FIG.11. In practice, removal of the mandrels 13 can be facilitated by makingthe cut in the filament-wound or tape-wrapped covering of graphitefibers on each mandrel 13 (preferably on a straight portion thereof nearthe top end of each mandrel 13 in the vicinity of the hole 22) beforethe mandrels 13 are inserted into the corresponding interstices of thegrid structure. After the mandrels 13 have been removed, the portions ofthe first ply extending beyond the grid structure are trimmed away by anappropriate Cutting technique, such as by using a diamond wire saw 24 asillustrated in FIG. 12.

A large-scale grid structure of the type shown in FIG. 1 can befabricated by bonding together a number of smaller-scale grid structuresmade according to the technique illustrated in FIGS. 2-12. Thus, asshown in FIG. 13, end portions of the planner grid sections of twosmaller-scale grid structures that are to be joined together to form alarger-scale grid structure are cut so as to provide tabs on each of theplanar grid sections. The two smaller-scale grid structures are thenpositioned so that the tabs on the end portions of the grid sections ofone of the smaller-scale grid structures are interleaved with the tabson the end portions of the grid sections of the other of thesmaller-scale grid structures. A "prepreg" tape containing graphitefibers embedded in an uncured epoxy matrix is then positioned on oneside of the interleaved tabs. The "prepreg" tape is then pressed againstthe tabs by a conventional clamping technique, and the epoxy resin iscured.

Three steps in the procedure for joining two smaller-scale gridstructures to form a larger-scale grid structure are illustrated in FIG.14. In the first step shown in FIG. 14 as step (A), tabs on the endportions of planar grid sections of one grid structure are positioned ininterleaving contact with tabs on the end portions of mating planar gridsections of another grid structure. Then, in the second step shown inFIG. 14 as step (B), an epoxy resin-impregnated tape of graphite fibersis applied to the interleaved tabs so that the graphite fibers of thetape extend generally orthogonally with respect to the graphite fiberson the interleaved tabs. Finally, in the third step shown in FIG. 14 asstep (C), the "prepreg" tape is clamped against the interleaved tabs bymeans of a conventional clamping device. A number of smaller-scale gridstructures can be joined together according to the technique illustratedin FIG. 14 to form a large-scale grid structure of desired size andconfiguration. The large-scale grid structure thereby formed is thenplaced in an oven for curing of the epoxy resin on the tape. When curingof the epoxy resin has been completed, the large-scale grid structure istaken from the oven and the clamping devices are removed.

An alternative technique for fabricating a three-dimensional gridstructure according to the present invention is indicated in FIG. 15(and illustrated in more detail hereinafter in FIG. 40). According tothis alternative technique, crisscrossing tapes or rovings consisting ofepoxy resin-impregnated graphite fibers extend in two different (e.g.,orthogonal) directions between corresponding pairs of reels, which arearrayed so that the tapes or rovings extending in each direction are"stacked" with respect to each other to form intersecting planesdefining the interstices of the grid structure. Mandrels covered withtapes or rovings consisting of the same kind of epoxy resin-impregnatedgraphite fibers are then inserted into the interstices defined by theintersecting planes. Then, heat is applied to cure the epoxy resin. Theuse of tapes or rovings of epoxy resin-impregnated graphite fibersinstead of graphite filaments eliminates the need to apply liquid epoxyresin.

Grid structures of various configurations can be fabricated using thetechnique of the present invention. The configuration of any particulargrid structure depends upon the arrangement of the posts 12 on the frame11 of the loom 10. FIGS. 16-20 illustrate various configurations forgrid structures that can be fabricated using corresponding arrangementsof the post 12. FIG. 16 is a sketch of a grid structure whoseintersecting grid sections define interstices of square cylindricalconfiguration. FIG. 17 is a sketch of a grid structure whoseintersecting grid sections define interstices of rhomboidallycylindrical configuration. FIG. 18 is a sketch of a grid structure whoseintersecting grid sections define interstices of triangularlycylindrical configuration. However, the grid sections defining theinterstices of a grid structure according to the present invention neednot necessarily be planar. Thus, in FIG. 19, a grid structure having asingle arcuate row of interstices is illustrated. FIG. 20 illustrates agrid structure whose interstices are arranged in arcuate rows andwedge-shaped columns, where each of the interstices is defined by twocurved grid surfaces having coaxially cylindrical surfaces of differentradii with respect to a cylindrical axis, and by two planar gridsections extending radially in different directions from the cylindricalaxis.

In FIG. 21, a loom is illustrated that can be used to fabricate athree-dimensional grid structure with rhomboidally cylindricalinterstices as shown in FIG. 17. In principle, the loom illustrated inFIG. 21 operates in substantially the same manner as the loomillustrated in FIG. 6. The arrangement of the vertical posts on the loomof FIG. 21 ensures that the interstices of the grid structure formedthereon are rhomboidally cylindrical, and the mandrels (whetherfilament-wound or tape-wrapped) inserted into the interstices arecorrespondingly of rhomboidally cylindrical configuration. A graphitefilament is shown wound around the vertical posts of the loomillustrated in FIG. 21 to form the grid sections of a grid structure ofthe type sketched in FIG. 17.

In FIG. 22, a loom is illustrated that can be used to fabricate athree-dimensional grid structure with triangularly cylindricalinterstices as shown in FIG. 18. In principle, the loom illustrated inFIG. 22 also operates in substantially the same manner as the loomillustrated in FIG. 6. The arrangement of the vertical posts on the loomof FIG. 22 ensures that the interstices of the grid structure formedthereon are triangularly cylindrical, and the mandrels (whetherfilament-wound or tape-wrapped) inserted into the interstices arecorrespondingly of triangularly cylindrical configuration. The path of agraphite filament being woven around the vertical parts on the loom ofFIG. 22 to form the grid sections of a grid structure of the typesketched in FIG. 18 is illustrated in FIG. 23.

A loom that can be used to fabricate the arcuate three-dimensional gridstructure shown in FIG. 19 is illustrated in FIG. 24. In principle, theloom of FIG. 24 operates in substantially the same manner as the loom ofFIG. 6, except that certain specialized mechanical features are providedon the loom of FIG. 24 to accommodate the arcuate configuration of thegrid structure. Thus, the loom of FIG. 24 comprises a planar frame 41upon which an arcuate groove 42 is provided on a surface portionthereof. Four posts 43, 44, 45 and 46 extend vertically from the frame41, so that the posts 43 and 44 are mounted on one side of the groove 42and the posts 45 and 46 are mounted on the other side of the groove 42.The posts 43 and 45 are positioned collinearly along a first radius ofthe arcuate groove 42, and the posts 44 and 46 are positionedcollinearly along a second radius of the arcuate groove 42. The posts 43and 44 lie on a first arc concentric with (but of shorter radius than)the arcuate groove 42, and the posts 45 and 46 lie on a second arcconcentric with (but of longer radius than) the arcuate groove 42.

A plurality of mandrels 47 are provided, which are configured anddimensioned to define the interstices of the grid structure. As shown inFIG. 25, each mandrel 47 has a planar top surface, a generally planarbottom surface with an arcuate tongue 48 projecting therefrom, twoplanar side surfaces, and two curved side surfaces. The planar top andbottom surfaces of each mandrel 47 are parallel to each other, and thetongue 48 projecting from the bottom surface is configured anddimensioned to be received in the arcuate groove 42 on the surface ofthe frame 41. The two planar side surfaces of each mandrel 47 lie oncorrespondingly different radii of the accurate groove 42 when themandrel 47 is positioned so that the tongue 48 is received in thearcuate groove 47. The two curved side surfaces of each mandrel 47 areconcentric with each other at correspondingly different radial distancesalong radii of the arcuate groove 42.

A cylindrical pin hole is provided on each of the curved side surfacesof each mandrel 47, and end blocks 49 and 50 are dimensioned andconfigured to cover corresponding side surfaces. Cylindrical couplingpins (shown in phantom outline in FIG. 25) project from the end blocks49 and 50, and are configured and dimensioned to be received incorresponding pin holes on the curved side surfaces of the mandrel 47.The mandrels 47 are wound with graphite filaments (or wrapped with"prepreg" tape consisting of graphite fibers) as indicated in FIG. 25.The orientation of the graphite filaments on the mandrels 47 (whetherfilament-wound or tape-wrapped) is generally orthogonal with respect tothe orientation of the portions of the graphite filament comprising thegrid sections formed on the loom shown in FIG. 24.

The mandrels 47 are positioned adjacent each other in an arcuatearrangement along the groove 42 on the frame 41 between the verticalposts 43 and 45 at one end thereof and the vertical posts 44 and 46 atthe other end thereof, as shown in FIG. 24. The end blocks 49 and 50 arepositioned adjacent corresponding curved side surfaces of each of themandrels 47, so that the coupling pins projecting from the end blocks 49and 50 enter the pin holes on the corresponding curved side surfaces ofthe mandrel 47. The depth of the pin holes and the length of thecoupling pins are predetermined so that the coupling pins cannot fullyenter into the pin holes, but instead go only partway into the pin holesso as to maintain a gap between each of the end blocks 49 and 50 and thecorresponding curved side surfaces of the mandrel 47 adjacent thereto.In order to form a grid structure having interstices of the requiredconfiguration, a graphite filament is then wound around the posts 43,44, 45 and 46, the mandrels 47, and the end blocks 49 and 50 in a pathas indicated in FIG. 26. As the graphite filament is woven in furthersuccessive paths as indicated in FIG. 26, a grid structure having thearcuate configuration sketched in FIG. 19 is formed.

After the weaving process on the loom of FIG. 24 has been completed,liquid epoxy resin is then applied so as to impregnate the graphitefilaments on the mandrels 47 and the portions of the woven graphitefilament comprising the grid sections formed on the loom. Theresin-impregnated graphite filaments are then compressed by a clampingdevice as illustrated in FIG. 24, and the loom with the compressedresin-impregnated graphite filaments thereon is placed in an oven at anappropriate temperature for a suitable length of time to cure the epoxyresin.

The clamping device shown in FIG. 24 comprises a fixed abutment member51 having an arcuate surface against which the end blocks 50 abut, amovable abutment member 52 having an arcuate surface that can bepositioned to abut the end blocks 49, and an anchoring member 53. Thefixed abutment member 51 is secured (as by screws) to the frame 41 at aposition radially outward of the arcuate groove 42. The movable abutmentmember 52 is positioned on the frame 41 radially inward of the arcuategroove 42, and the anchoring member 53 is secured (as by screws) to theframe 41 at a position radially inward of the movable abutment member52. An adjustment screw 54, which extends through the anchoring member53 into the movable abutment member 52, enables the movable abutmentmember 52 to be translated radially inward and outward over the surfaceof the frame 41. As the adjustment screw 54 is tightened, the bottomportions of the end blocks 49 are pressed against the mandrels 47.

A cover frame 55 (which is analogous to the cover frame 19 shown in FIG.8) is fitted over the posts 43, 44, 45 and 46, and over the mandrels 47and the end blocks 49 and 50, after the graphite filaments have beensaturated with liquid epoxy resin. The cover frame 55 comprises an outerwall portion 56 having an arcuate surface against which the end blocks50 abut, and an inner wall portion 57 that is spaced apart from the endblocks 49. A movable abutment member 58 is positioned against anundersurface of the cover frame 55 in the space between the inner wallportion 57 and the end blocks 49, and is held in position by means of anadjustment screw 59 extending through the inner wall portion 57 of thecover frame 55 into the movable abutment member 58. The adjustment screw59 enables the movable abutment member 58 to be translated radiallyinward and outward against the undersurface of the cover frame 55. Asthe adjustment screw 59 is tightened, the top portions of the end blocks49 are pressed against the mandrels 47.

An anchoring member 60 is secured (as by screws) to the frame 41 so asto straddle the arcuate groove 42 in the vicinity of the posts 43 and 45outside an arcuate region whose corners are defined by the posts 43, 44,46 and 45. A movable abutment member 61 is positioned on the frame 41 soas to straddle the arcuate groove 42 in the space between the anchoringmember 60 and the particular mandrel 47 that is positioned adjacent theposts 43 and 45. An adjustment screw 62 passes through the anchoringmember 60 into the movable abutment member 61, and enables the movableabutment member 61 to be translated generally along the arcuate groove42 toward or away from the mandrel 47 positioned adjacent the posts 43and 45. The movable abutment member 61 is dimensioned to fit between theposts 43 and 45 so as to abut a bottom portion of the mandrel 47adjacent thereto. Similarly, an anchoring member 63 is secured (as byscrews) to the frame 41 so as to straddle the arcuate groove 42 in thevicinity of the posts 44 and 46 outside the arcuate region whose cornersare defined by the posts 43, 44, 46 and 45. A movable abutment member 64is positioned on the frame 41 so as to straddle the arcuate groove 42 inthe space between the anchoring member 63 and the particular mandrel 47that is positioned adjacent the posts 44 and 46. An adjustment screw 65passes through the anchoring member 63 into the movable abutment member64, and enables the movable abutment member 64 to be translatedgenerally along the arcuate groove 42 toward or away from the mandrel 47positioned adjacent the posts 44 and 46. The movable abutment member 64is dimensioned to fit between the posts 44 and 46 so as to abut a bottomportion of the mandrel 47 adjacent thereto.

On the cover frame 55, a sidewall portion (not shown in FIG. 24) extendsdownward into the space between the posts 43 and 45, and a sidewallportion 66 extends downward into the space between the posts 44 and 46.As indicated in FIG. 24, an adjustment screw 67 passes through thesidewall portion 66 of the cover frame 55 into a movable abutment member(not visible in FIG. 24) positioned in the space between the sidewallportion 66 and the mandrel 47 adjacent the posts 44 and 46. Theadjustment screw 67 enables the movable abutment member connectedthereto to be translated toward or away from the mandrel 47 adjacent theposts 44 and 46. Similarly, although not shown in FIG. 24, an adjustmentscrew passing through the sidewall portion of the cover frame 55 thatextends downward into the space between the posts 43 and 45 is connectedto a movable abutment member that can thereby be translated toward oraway from the mandrel 47 adjacent the posts 43 and 45. When theadjustment screw 67 is tightened, the movable abutment member connectedthereto abuts a top portion of the mandrel 47 adjacent the posts 44 and46; and when the adjustment screw passing through the sidewall portionat the other end of the cover frame 55 is tightened, the movableabutment member connected thereto abuts a top portion of the mandrel 47adjacent the posts 43 and 45.

When the cover frame 55 is in place over the posts 43, 44, 45 and 46,and over the mandrels 47 and the end blocks 49 and 50; and after theadjustment screws 54 and 59 have been tightened so as to applycompressional forces near the bottom and top ends, respectively, of theend blocks 49; and after the adjustment screws 62 and 65 have beentightened so as to apply compressional forces to the bottom portions ofthe mandrels 47; and after the adjustment screw 67 and the correspondingadjustment screw at the other end of the cover frame 55 have beentightened so as to apply compressional forces to the top portions of themandrels 47; the entire loom with the cover frame 55 in place thereon isthen inserted into an oven for curing of the epoxy resin. After theepoxy resin has been cured, the loom is taken from the oven and thecover frame 55 is removed. The mandrels 47 and the end blocks 49 and 50are then removed, and portions of the resulting graphite-epoxy compositestructure that are extraneous to the desired shape of the arcuate gridstructure as shown in FIG. 19 are trimmed away by conventional meanssuch as a diamond wire saw as illustrated in FIG. 27. A completedarcuate grid structure as formed on the loom of FIG. 24 is shown in FIG.28.

In FIG. 29, a loom is illustrated that can be used to fabricate a gridstructure as sketched in FIG. 20. The loom of FIG. 29 serves the samegeneral purpose as the looms of FIGS. 6 and 24, except that certainspecialized mechanical features are provided on the loom of FIG. 29 inorder to produce the required configuration of the grid structure inwhich the interstices are arranged in arcuate rows and wedge-shapedcolumns.

The loom of FIG. 29 comprises a planar frame 71 upon which an array offixed posts 72 and an array of movable posts 73 are mounted. The fixedposts 72 are arranged with respect to each other so that a graphitefilament can be woven by successive traversals of a path around thefixed posts 72 according to a pattern that produces generallywedge-shaped radially extending columns. The movable posts 73 aresecured in arcuate slots 74 arranged in corresponding pairs on the frame71 on opposite sides of the array of fixed posts 72. The movable posts73 of each pair are movable in their corresponding arcuate slots 74 frominitial positions, at which separate graphite filaments can be strung instraight lines between the movable posts 73 of corresponding pairs so asto extend transversely with respect to the filament woven around thefixed posts 72, to final positions at which the filaments strung betweenthe corresponding pairs of movable posts 73 are bent along arcuatepaths. In operation, after each successive transversal of the patharound the fixed posts 72 by the filament that forms the wedge-shapedcolumns, separate filaments are strung between corresponding pairs ofthe movable posts 73. Opposite ends of each of the separate filamentscan be secured to corresponding movable posts 73 by means of a clip 75,as shown in cross-sectional detail in FIG. 30.

After separate filaments have been strung between the correspondingpairs of movable posts 73, another traversal of the path around thefixed posts 72 is made by the filament that forms the wedge-shapedcolumns, after which another set of separate filaments is strung betweenthe corresponding pairs of movable posts 73. This process is repeateduntil a three-dimensional grid structure is formed having atwo-dimensional weave on each grid section thereof, where theinterstices of the grid structure are arranged in rectilinear rows andwedge-shaped columns. Then, after the filaments comprising the gridstructure are all in place on the loom, a first set of mandrels withlongitudinally extending graphite filaments on the surfaces thereof ispositioned in recesses provided therefor on the surface of the frame 71between a first pair of the movable posts 73. These mandrels could befilament-wound in the manner illustrated in FIG. 2 or tape-wrapped inthe manner illustrated in FIG. 3 to provide the longitudinally extendingfilaments on the surfaces thereof.

The mandrels (for which reference numbers are not provided in FIG. 29 soas to prevent excessive cluttering of the drawing) are configured sothat, when the movable posts 73 of the first pair are moved to theirfinal position, the graphite filaments strung between the movable posts73 of the first pair are thereby bent to assume a desired arcuateconfiguration. Then, a second set of mandrels with longitudinallyextending graphite filaments on the surfaces thereof is positioned inrecesses provided therefor on the surface of the frame 21 between asecond pair of the movable posts 73. The mandrels of the second set areconfigured to bear against the graphite filaments strung between themovable posts 73 of the first pair when bent into the desired arcuateconfiguration, and to bend the graphite filaments strung between themovable posts 73 of the second pair into an arcuate configuration thatis concentric with respect to the arcuate configuration of the filamentsstrung between the first pair of movable posts 73 when the movable posts73 of the second pair are moved to their final position. In like manner,additional sets of mandrels with longitudinally extending graphitefilaments on the surfaces thereof are successively positioned inrecesses provided therefor on the surface of the frame 71 aftercorresponding pairs of movable posts 73 are successively moved to theirfinal positions in the slots 74.

The above-described procedure for forming a grid structure of the kindillustrated in FIG. 20 on a loom of the type shown in FIG. 29 isillustrated schematically in FIGS. 31A, 31B and 31C. Thus, in FIG. 31A,the filaments that are strung between corresponding pairs of the movableposts 73 transversely across the filament woven around the fixed posts72 are shown as straight lines forming rectilinear rows of interstices.The first set of mandrels is shown in place in FIG. 31A, and the firstpair of movable posts 73 is shown being moved to final positions 73'indicated by broken-line circles. Movement of the first pair of posts 73to their final positions 73' causes the filaments strung between thefirst pair of movable posts 73 to assume an arcuate shape as indicatedby a broken-line arc.

In FIG. 31B, the second set of mandrels is shown in place on the frame71, and the second pair of movable posts 73 is shown being moved tofinal positions 73' at which the filaments strung between the secondpair of movable posts 73 are caused to assume an arcuate shape (asindicated by a broken-line arc) that is concentric with respect to thearcuate shape of the filaments strung between the first pair of movableposts 73. In FIG. 31C, the third set of mandrels is shown in place onthe frame 71, and the third pair of movable posts 73 is shown beingmoved to final positions 73' so that the filaments strung between thethird pair of movable posts 73 are likewise caused to assume an arcuateshape. Additional sets of mandrels are positioned in succession on theframe 71, and the filaments strung between successively moved pairs ofmovable posts 73 are likewise caused to assume arcuate shapes, whereby agrid pattern is formed having arcuate rows and wedge-shaped columns.

With reference again to FIG. 29, liquid epoxy resin is applied to thegraphite filaments forming the grid structure (viz., the filament wovenaround the fixed posts 72, the filaments strung between correspondingpairs of the movable posts 73, and the filaments wound or wrapped aroundthe surfaces of the mandrels). Clamping devices mounted on the loom, asshown in FIG. 29, are then tightened to apply compressional forces tothe mandrels, and a cover frame (not shown in FIG. 29) is then placedover the posts 72 and 73. The entire loom with the cover frame in placeis then inserted into an oven for curing of the epoxy resin. After theepoxy resin has cured, the mandrels are removed from the interstices ofthe resulting graphite-epoxy composite structure, and the compositestructure is removed from the loom. Portions of the composite that areextraneous to the desired shape of the grid structure as shown in FIG.20 are then trimmed away.

It is possible to provide orientations other than mutually orthogonalorientations for the graphite filaments in the various grid sections ofa grid structure according to the present invention. Thus, an exemplaryeggcrate-type grid structure is illustrated in FIG. 32 in which thefilament woven to form the grid sections defining the interstices of thegrid structure extends in directions that are non-perpendicular to theelongate axes of the interstices into which the filament-wound (ortape-wrapped) mandrels are inserted. In FIG. 33, the grid sectionsdefining the interstices of the grid structure are formed from afilament woven so as to criss-cross itself on each grid section indirections non-perpendicular to the elongate axes of the interstices.

In FIG. 34, an illustration is provided of a loom suitable for weaving afilament into a pattern as shown in FIG. 33. The loom is FIG. 34comprises a generally planar annular frame 81 with a first set of posts82 and a second set of posts 83 extending vertically in one direction(i.e., upward) therefrom, and a third set of posts 84 and a fourth setof posts 85 extending vertically in the opposite direction (i.e.,downward) therefrom. The first and second sets of posts 82 and 83 aresecured to the annular frame 81 around a first semicircular arc thereof,and the third and fourth sets of posts 85 and 86 are secured to theannular frame 81 around a second (i.e., the opposite) semicircular arcthereof. Protuberances extend from each of the posts of the sets 82, 83,84 and 85 inwardly with respect to the annular frame 81 at a specifiedangle (e.g., 45 degrees) with respect to the plane of the annular frame81.

One end of a graphite filament is secured by means of a clip 86 to theprotuberance extending from a first post of the set 82, and is wovenaround the protuberance extending from a corresponding first post of theset 84, and is then woven successively around the protuberancesextending from second posts of the sets 82 and 84, and then around theprotuberances extending from third posts of the sets 82 and 84, untilthe filament is wound around the protuberances extending from the lastposts of the sets 82 and 84, whereupon the other end of the filament issecured by means of a clip (not visible in the perspective of FIG. 34)to the protuberance extending from the last post of the set 84.Similarly, another graphite filament is woven around correspondingprotuberances extending from the sets of posts 83 and 85. One end ofthis other graphite filament is secured by means of a clip 87 to theprotuberance extending from a first post of the set 83, and the otherend of this other graphite filament is secured by means of a clip (notvisible in FIG. 34) to the protuberance extending from the last post ofthe set 85. The two graphite filaments repeatedly crisscross each otherto form intersecting grid sections defining the interstices asillustrated in FIG. 33. Mandrels (either filament-wound or tape-wrapped)of the type generally illustrated in FIG. 6 are then inserted intocorresponding interstices.

The depth of the interstices of a grid structure formed on the loomillustrated in FIG. 34 is determined by the amount of filamentarymaterial wound onto the protuberances extending from the sets of posts82, 83, 84 and 85 secured to the annular frame 81 (which is related tothe length of the protuberances), and by the amount of filamentarymaterial wound onto the mandrels (which is related to the length of themandrels) inserted into the intersecting grid sections formed by thecrisscrossing filaments to define the interstices. Grid structureshaving very deep interstices can be fabricated by stacking a desirednumber of annular frames 81 on a planar base frame 88 in an arrangementas illustrated in FIG. 35. The base frame 88 could be mounted on anelevator mechanism as indicated in FIG. 35 to facilitate assembly ofstacked annular frames 81 on the base frame 88, and to facilitateweaving of the crisscrossing graphite filaments around the protuberanceson the corresponding sets of posts 82, 83, 84 and 85 extending from theannular frames 81. As successive annular frames 81 are added topreviously stacked annular frames 81, the base frame 88 can be lowered(as indicated by the arrows in FIG. 35) to accommodate the convenienceof workers performing the stacking and weaving. Elongate mandrels 89(either filament-wound or tape-wrapped) are then inserted into thecorresponding interstices defined by the intersecting grid sectionsformed by the crisscrossing graphite filaments. The graphite filamentswoven around protuberances extending from posts secured to the baseframe 88 and from posts secured to the annular frames 81, as well as thegraphite filaments wound or wrapped around the mandrels 89, are thensaturated with epoxy resin.

In FIG. 36, clamping devices 90 and 91 are illustrated, which are usedto apply compressional forces in two mutually orthogonal directionsagainst the mandrels 89. Each of the clamping devices 90 is one of a setof four load-transferring appliances, which are mounted on the planarbase frame 88 so as to apply compressional forces against bottom endportions of the mandrels 89 that are received in an aperture providedtherefor in the base frame 88. In the particular embodiment illustratedin FIG. 36, each clamping device 90 comprises a bar that can be drivenby means of a piston into contact with the bottom end portions of anouter row of the mandrels 89.

Each of the clamping devices 91 shown in FIG. 36 is one of a set of fourload-transferring appliances positioned in generally coplanardisposition with respect to each other at an intermediate position alongthe length of the mandrels 89. In the particular embodiment illustratedin FIG. 36, each clamping device 91 comprises a set of parallel rodsextending from a holding block. Each rod passes between a correspondingpair of intersecting grid sections formed by the crisscrossing graphitefilaments so that a distal end thereof bears against a mid-lengthportion of a corresponding outer-row mandrel 89. For exceptionally longmandrels 89, there can be additional sets of clamping devices 91 (withfour clamping devices 91 to each set) positioned at various, preferablyregularly spaced, intervals along the length of the mandrels 89. A pairof retaining clamps 92 and 93 is provided adjacent top end portions ofthe mandrels 89 to apply compressional forces thereto in mutuallyorthogonal directions.

FIG. 37 shows a particular type of oven 94 that can be used for curingthe epoxy resin that saturates the graphite filaments forming the gridsections defining the interstices of the grid structure as well as thegraphite filaments on the mandrels 89. The oven 94 comprises acylindrical wall that is dimensioned to be lowered in place around thestacked annular frames 81 on the base frame 88. Wheel-rotated shaftspass through the oven wall to drive the clamping devices 90 toward oraway, as desired, from the bottom end portions of the mandrels 89.Similarly, wheel-rotated shafts pass through the oven wall to bearagainst the holding blocks to which the parallel rods of the clampingdevices 91 are attached so as to drive the rods toward or away, asdesired, from the mid-length portions of the mandrels 89. Access to theretaining clamps 92 and 93 is provided by a hinged lid 95 forming thetop wall of the oven 94. The bottom wall of the oven 94 is formed by thebase frame 88.

A transverse cross-sectional view at the top of the oven 94 is shown inFIG. 38 in which the retaining clamps 92 and 93 are illustrated. Atransverse cross-sectional view at a mid-portion of the oven 94 is shownin FIG. 39 in which the clamping devices 91 are illustrated.

A continuous process apparatus is illustrated in FIG. 40 for fabricatinga grid structure of eggcrate configuration from tapes of epoxyresin-impregnated graphite filaments. However, in the simplifiedillustration of FIG. 40, no means is shown for applying lateralcompressional forces to the mandrels positioned in the intersticesdefined by the grid sections formed by the intersecting "prepreg" tapesof graphite filaments. In FIG. 41, a means for applying lateralcompressional forces to the mandrels is illustrated.

A schematic depiction of the operation of the continuous-processapparatus of FIG. 40 is provided in FIG. 42. As diagrammaticallysummarized in FIG. 43, which can be viewed in conjunction with FIG. 42,the process of fabricating a grid structure according to the presentinvention using an apparatus of the type illustrated in FIGS. 40 and 41comprises the successive steps of:

1) Loading reels of "prepreg" graphite tapes onto spindles arranged sothat a specified number of spaced-apart tapes forming planar gridsections of the grid structure extend longitudinally betweencorresponding pairs of reels, where the number of tapes extendinglongitudinally between each pair of reels determines the depth of theinterstices of the grid structure;

2) Loading other reels of "prepreg" graphite tapes onto other spindlesarranged so that the same specified number of spaced-apart tapes can beextended laterally (as by means of a conventional shuttle device)between corresponding pairs of reels, where the laterally extendingtapes are interleaved between the longitudinally extending tapes to formthe intersecting grid sections defining the interstices of the gridstructure;

3) Clipping the laterally extending tapes adjacent outside rows of thelongitudinally extending tapes;

4) Wrapping elongate mandrels with "prepreg" graphite tapes that extendparallel to the direction of elongation of the mandrels;

5) Inserting the tape-wrapped mandrels into corresponding interstices ofthe grid structure;

6) Applying longitudinal compressive forces on the mandrels;

7) Applying lateral compressive forces on the mandrels;

8) Applying heat to cure the epoxy resin impregnating the graphitefibers on the "prepreg" tapes extending between corresponding pairs ofreels and wrapped around the mandrels;

9) Removing heat when the epoxy resin has been cured;

10) Removing the longitudinal and lateral compressive forces on themandrels;

11) Removing the mandrels from the interstices of the grid structure;and

12) Trimming away portions of the grid structure thereby formed that areextraneous to the desired final configuration for the grid structure.

Many different types of grid structures for use in various types ofapplications can be fabricated by techniques as described andillustrated herein. In FIG. 44, a proposed spacecraft is shown on whichgrid structures according to the present invention would be utilized:e.g., an optical bench 96, a mirror support structure 97, struts 98,see-through trusses 99, and sandwich-type panels 100.

Particular embodiments of grid structures fabricated according to thepresent invention have been described in the foregoing specification andaccompanying drawing. However, grid structures according to the presentinvention having different configurations suitable for differentapplications would become apparent to practitioners skilled in the artupon perusal of the specification and drawing. Therefore, thedescription presented herein is merely illustrative of the invention,which is more generally defined by the following claims and theirequivalents.

We claim:
 1. A grid structure made from a composite materialsubstantially consisting of filamentary material embedded in a matrix,said filamentary material extending three-dimensionally in at leastthree different directions in said matrix, said grid structure beingfabricated by a process comprising the steps of:a) arranging filamentarymaterial according to a predetermined pattern to define interstices forsaid grid structure, said filamentary material consisting of fibrousfilaments extending so as to define cross-sectional configurations forsaid interstices, substantially all fibrous filaments that extend in aparticular one of said directions according to said predeterminedpattern maintaining a generally constant separation from each other overan extent that is longer than a plurality of said interstices; b)covering each one of a plurality of mandrels individually withfilamentary material consisting of fibrous filaments, said mandrelsconforming in cross-sectional configuration to said interstices definedby said predetermined pattern, said fibrous filaments of saidfilamentary material covering said mandrels being arranged on saidmandrels so as to extend predominantly transversely with respect to saidfibrous filaments of said filamentary material arranged to define saidinterstices when said mandrels are inserted into said interstices; c)inserting said mandrels covered with said filamentary material intocorresponding interstices defined by said predetermined pattern; d)causing said filamentary material arranged to define said intersticesand said filamentary material covering said mandrels in saidcorresponding interstices to be impregnated with a matrix material; e)applying compressional forces to said filamentary material impregnatedwith said matrix material between adjacent mandrels, said compressionalforces being substantially entirely perpendicular to said fibrousfilaments of said filamentary material covering said mandrels when saidmandrels have been inserted into said corresponding interstices: f)curing said matrix material that has impregnated said filamentarymaterial, thereby forming an integral structure made of said compositematerial consisting of said filamentary material embedded in saidmatrix; and g) removing said mandrels from said interstices.
 2. The gridstructure of claim 1 wherein said filamentary material covering each oneof said mandrels is preformed into tape, said tape being wrapped aroundeach one of said mandrels.
 3. The grid structure of claim 1 wherein saidprocess comprises the further step of trimming away portions of saidintegral structure that are extraneous to a desired configuration forsaid grid structure.
 4. The grid structure of claim 1 wherein saidfibrous material is a material selected from a group consistingsubstantially of graphite, aramide, fiberglass, ceramic material,metallic material, and thermoplastic material.
 5. The grid structure ofclaim 4 wherein said matrix material is a material selected from a groupconsisting substantially of thermosetting resins and thermoplasticmaterials.
 6. The grid structure of claim 5 wherein said thermosettingresins include epoxy, polyester, phenolic and polyimide.
 7. A gridstructure formed from a composite material so as to have intersticesdefined by intersecting surfaces, said intersecting surfaces comprisingfibers embedded in a matrix, said fibers extending three-dimensionallyin at least three different directions in said matrix to definecross-sectional configurations for said interstices, substantially allfibers that extend in a particular one of said different directions insaid matrix having a generally uniform separation from each other overan extent that is longer than a plurality of said interstices.
 8. Thegrid structure of claim 7 wherein said intersecting surfaces define apredetermined configuration for said grid structure.
 9. The gridstructure of claim 7 wherein said predetermined configuration for saidgrid structure is geometrically regular.
 10. The grid structure of claim9 wherein said predetermined configuration for said grid structureresults in interstices of rectangular cross section.
 11. The gridstructure of claim 9 wherein said predetermined configuration for saidgrid structure results in interstices of rhomboidal configuration. 12.The grid structure of claim 9 wherein said predetermined configurationfor said grid structure results in interstices of triangularconfiguration.
 13. The grid structure of claim 9 wherein saidpredetermined configuration for said grid structure results ininterstices of arcuate configuration.
 14. The grid structure of claim 9wherein said predetermined configuration for said grid structure resultsin interstices arrayed in arcuate rows and wedge-shaped columns.